Graco 312878J User's Manual
Contents
1. IVOINVH23WW N HDLIMS TWOINVHDIW orf v SS3NHVH TOYLNOD 51 YOLOW d Lf SSINYVH 3HUIM GNNOYD HOSN3S 1 NOWWO 319 2 1 1 ANIHDVW 1 HOSN3S A Ave NOLLISOd Aldd s E YIMOd AvZ YYINIT NOWWOD J18v2 NNO HOLO3NNOD SSANYVH YIMOd V V 33110341 02 LOHS 1 5 OL d3MOd OL318V5 VIVO JUNSOTINA 1921812313 TIOULNOD LOHS ees Simplified Schematic Shot Controller Electrical me 19 312878J Conversion Kit Installation Simplified Schematic Alternate Gun Connection SHOT CONTROLLER ELECTRICAL ENCLOSU COIL RETURN SOLENOID VALVE DISPENSE COMMAND DISPENSE REQUEST ACTIVE SWITCH RETURN es X NORMALLY OPEN SWITCH GUN TRIGGER 20 RE ti12350a 312878J Setup Hydraulic Proportioner Setup See hydraulic proportioner manual 312062 Controller Setup When in any of the setup screens pouring is dis abled To enter the setup screens press and hold the top soft key for three seconds To exit the setup screens press and hold both soft keys for three seconds See FIG 2 on page 8 for HMI button identification To navigate between the setu2. 253727 255400 255401 255402 255406 255407 253725 253726 253727 255400 255401 Conversion Kit 24A024 24A024 24A024 24 024 24 024 24 024 24 024 24 024 24 024 24 024 24 024 24 024 255825 24 024 255826 24 024 Hydraulic Proportioner Refer to hydraulic proportioner repair manual 312063 for parts lists for each hydraulic proportioner Conversion Kit 24A024 227 ti11786a ti11759a FiG 18 34 312878J Ref T5 2 3 4 5 6 7 8 9 10 11 12 13 14 15 161 171 181 191 201 21 22 262416 256217 256230 287839 157859 121002 151852 151602 189930 before use Parts included in Kit 24A071 which can be pur chased separately Description PENDANT shot meter KIT bracket pendant ENCLOSURE electrical assy SENSOR assembly KIT holder magnet BRACKET mounting linear sensor BRACKET mounting magnet SPACER bracket magnet PLATE clamp bracket magnet SCREW cap sch NUT lock hex SCREW cap hex hd WASHER lock spring WASHER plain NUT head CABLE shot controller data DB25 10 ft CABLE shot controller power female female 3 0 m CABLE gun DB9 25 ft CABLE gun DB9 10 ft ADHESIVE anaerobic PLATE activator asm LABEL caution T Parts not shown Qty a NNNNA Software token 24F322 is required to install software Re
3. Hydraulic Proportioner Operation Manual 312063 Reactor Hydraulic Proportioner Repair Parts Manual Reactor Electric Diagrams Pan Description 312064 Reactor Hydraulic Proportioner Electrical Diagrams AR Pour Gun Pat Description _ 312888 AR Pour Gun Operation Parts Manual Proportioning Pump 312068 Proportioning Pump Repair Parts Manual 312878J Models Models IPH 25 SERIES Max Flow X Approximate Maximum Fluid Full Load Primary Rate Output per Hydraulic Working Peak Amps System Heater Ib min Cycle Pressure Pressure Per Phase Watts Watts kg min gal liter Ratio psi MPa bar 255814 B 69 230V 1 15960 18000 22 10 0 063 0 24 1 91 1 2000 13 8 138 255815 B 230V 3 N gt 115960 8000 22 10 0 063 0 24 1 91 1 2000 13 8 138 255816 35 400V 3 15960 18000 22 10 0 063 0 24 1 91 1 2000 13 8 138 255819 100 230 1 123260 15300 22 10 0 063 0 24 1 91 1 2000 13 8 138 1 255820 89 230 1 23260 15300 22 1 0 063 0 24 1 91 1 2000 13 8 138 1 0 0 0 0 0 0 ees wr w n wr w w n 255824 B 69 230V 1 15960 18000 22 10 0 063 0 24 1 91 1 2000 13 8 138 255825 B 46 1230 3 15960 18000 22 10 0 063 0 24 1 91 1 2000 13 8 138 IPH 40 SERIES Approximate Maximum Fluid Full Load Primary Output per Hydraulic Working Part Peak Amps Heater Cycle Pressure Pressure Series Per Pha
4. Standby mode the machine can be brought back to full pressure in one of two ways e Not recommended Trigger a shot The system will sense the pressure drop and the motor will ramp up to full speed Shot may be inaccurate e Recommended Press on the Motor Controls to turn the motor circuit OFF then press it again to turn it back ON This will cancel Standby mode and restart the motor Wait for the Reactor to regain full pressure before triggering a shot 312878J Conversion Kit Installation 17 Conversion Kit Installation Simplified Schematic Shot Controller Wiring FG FB FH FC N FF e BE A FE FD A See FIG 18 on page 34 for detailed view Key FA Shot Controller FF Hydraulic Proportioner Motor Control FB Hydraulic Proportioner Fan Fuse Block Board FC Electrical Enclosure FG Shot Controller Power Cable FD Hydraulic Proportioner Temperature FH Port for Optional Data Reporting Kit Control Board 248848 purchase separately view from front of hydraulic proportioner FJ Port for External Machine Control FE Linear Sensor FK Shot Controller Data Cable FL Port for Gun Cable 11 25 H40 Conversion Kit Wiring Diagram 18 312878J Conversion Kit Installation uonejedo Aeids pueog DNI LHOd3H O1JUOD JOJO UO Gf 0 SSeuueu VW VIVO IVWNOILdO 112349 o o o o a 1OdLNOD YOLOW 573 SSANYVH HOLIMS 4
5. modes Shot Sh and Manual will always be available and Sequence mode Sq X will be available when one or more sequences are created by the user See Setup Screen 3 Shot Sequences on page 21 To change the operating mode hit the Mode Select key on the HMI until the desired operating mode is shown in the top left corner of the screen Hit the top soft key to confirm the mode selection Operation Change Shot Number Only shots with non zero volumes weights can be selected To change the selected shot from the idle run screen hit the up or down arrow keys When the desired shot is selected hit the top soft key to confirm the selection Change Shot Volume Weight To change the defined shot volume or weight for the selected shot first enter Run Screen Shot Editing mode by pressing and holding both the up and down arrow keys for three seconds Use the up and down arrow keys to change the shot volume weight then confirm the change when prompted changing the operating mode or shot number the item being changed will be highlighted A During Run Screen Shot Editing the shot quantity will be highlighted A A password may be required to edit this item A All changes must be confirmed or cancelled 16 Run Screen Shot Editing Changing Operating Mode 312878J 29 Operation Sequence Mode Options Calibration The Shot Meter dispenses a programmed shot amount based on the measured motion
6. of time it is grounded meaning the pattern followed should be x mS grounded x mS ungrounded x mS grounded x mS ungrounded etc The allowable range for the period of time Pin 7 is ground ungrounded is 10 to 100 milliseconds To request shot n or the n shot within the selected sequence Pin 7 must be connected to and then dis connected from Pin 1 n 7 times For example to request shot 3 Pin 7 must be grounded four times 312878J Setup After Pin 7 has been grounded n 1 times there must be a delay of four times the period Pin 7 was grounded for each of the n 7 repetitions For example if Pin 7 was grounded for 15 milliseconds then ungrounded for 15 milliseconds and so on there must be a delay of 60 milliseconds before activating the Dispense Request line 27 Setup Pin 7 Shot Number or Sequence Shot Request Not Grounded Grounded 4 X 15 mS Pin 8 Dispense Request Not Grounded Grounded Dispensing begins Pin 9 Ready Status 24V signal 5V signal 0 15 30 45 60 75 90 105 120 180 280 330 TIME milliseconds 15 Timing Diagram Example Request and Dispense Shot 3 28 312878J Operation The AR Pour Gun and shot controller modify the hydraulic proportioner to pour instead of spray but all operation procedures from hydraulic proportioner operation manual 312062 are applicable Startup See hydraulic proportioner operation manual 312062 Change Operating Mode Operating
7. some use ISO on the B side e Epoxies often have amines on the B hardener side Polyureas often have amines on the B resin side 3128784 Component Identification Component Identification IPH System _ 1 9 j N OY ti11820a b gt X 7 Fic 1 IPH System with Front Cover Removed Qe vom 7 oO A e Si 6 Model 255811 shown X E ozro tiga 8 2 A ogc S0 o O o gt LS L OUJ gt Y lt 3128784 Component Identification Human Machine Interface HMI AB AC FiG 2 Key AA Up arrow key AB Down arrow key AC Mode select button AD Top soft key NOTICE To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails Initiate Shot button Pressing this button will start a shot for either the selected shot number the next shot number in the selected sequence or when in manual mode will dis pense until the user releases the button This button is initially set as disabled and can be enabled or disabled from setup screen 7 See Setup Screen 7 Enable Disable Run Screen Shot Editing or Initiate Shot button on page 23 AG AD AF AE Bottom soft key AF Initiate shot button AG L
8. Aw amp Spraying materials containing isocyanates creates potentially harmful mists vapors and atomized par ticulates Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventila tion in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate per sonal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition Some materials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component foam and polyurea coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in viscosity If used this partially cured ISO will reduce performance and the life of all wetted parts The amount of film formation and rate of crystalli zation varies depending on the blend of ISO the humidity and the
9. CD screen Mode Select button Pressing this button will allow selection of an operating mode The available choices will always include Shot Sh and Manual Mn If one or more sequences have been programmed the Sequence modes available will show up as the name of each sequence Sq A Sq B etc 312878J Component Identification Icons General Icons Setup screen 1 Setup screen 3 Run screen when Learn Mode is enabled Previous Setup screen 1 NR Run screen when Learn Mode is enabled L NEUE un Active Indicator shown in lower left NER EE Setup Icons see Controller Setup section on page 21 0 Reset Piston Counter to Zero Setup screen 1 Define Shot Amount e Setup screen 2 Change Password e Setup screen 5 Enable Tap mode Setup screen 6 Enable Hold mode Setup screen 6 Enable Initiate Shot button on HMI Setup screen 7 Disable Initiate Shot button on HMI Setup screen 7 Enable Run Screen Shot Editing Setup screen 7 312878J 9 Component Identification Disable Run Screen Shot Editing e Setup screen 7 Enter Learn Mode e Setup screen 8 Exit Learn Mode e Setup screen 8 10 312878J Run Screen BA BBA BM BL Component Identification BC BD BE BG A When no errors are active E will be displayed A Shown only during shot dispensing in Shot or Sequence mode A Displayed only in Sequence mode BA
10. Current operating mode n shot in sequence BC Number of shots executed for selected shot number BD Quantity of selected shot Shot or Sequence modes or previous shot Manual mode BE Quantity unit of measure cubic centimeters or grams BF Top soft key icon BG Bottom soft key icon BH Duration of selected shot Shot or Sequence modes or previous shot Manual mode BJ Progress bar for current shot BK Error status BL Piston position BM Shot number currently selected Fic 3 Run Screen Run Screen Variables Available operating modes vary by setup but will include Sh for predefined shot mode and Mn for manual shot mode If sequences have been defined operating mode options will include Sq A Sq B etc to select any of the defined sequences See Change Operating Mode on page 29 Shot quantity can be displayed either in cubic centime ters or grams depending on whether specific gravity is entered See Setup Screen 6 Quantity Units and Gun Configuration on page 22 312878J The top and bottom soft key icons indicate the function of the respective soft key See Icons section on page 9 for icon descriptions 11 Component Identification Press u gt access Setup Screen 8 Enter and confirm correct password Setup Screen 1 Maintenance Mode Password Entry Press dow arrow ke This screen is skipped N Press and hold bottom o di c soft key for 2 sec when passw
11. Initiate Shot button allows starting and stopping shots from both the gun and the Initiate Shot button When operating with the Initiate Shot button enabled the gun must be locked in a pouring enclosure so that all dispensed material will be dis pensed in a direction away from people The system is shipped with the Initiate Shot but ton disabled To enable or disable Run Screen Shot Editing of the Ini tiate Shot button on the HMI navigate to setup screen 7 and push the top soft key Confirm the selec tion when prompted See Icons section on page 9 Setup Screen 8 Learn Mode See Learn Mode section on page 24 Setup Screen 10 Define Piston Size See Piston Size section on page 25 Password Protection The setup screens can be protected by a password to restrict their accessibility When the password is 00000 the setup screens can be accessed without entering a password To create a password to protect the setup screens or to change the existing password navigate to setup screen 5 and hit the top soft key to enter the password entry screen Enter the new password twice and then hit the top soft key to confirm To disable the password change the password to 00000 as described in the previous paragraph 312878J Setup To access the setup screens when the password is enabled press the top soft key for three second and the password entry screen will appear Enter th
12. Installation Operation G 7 GRACO Shot Controller For use with non flammable polyurethane foams For professional use only Not approved for use in European explosive atmosphere locations 2000 psi 13 8 MPa 138 bar Maximum Working Pressure Important Safety Instructions Proportioner shown includes Shot Controller Read all warnings and instructions this proportioner also available without Shot Controller manual and the Hydraulic Reactor Operation manual Save all instructions See page 3 for model information ti11756a PROVEN QUALITY LEADING TECHNOLOGY Related Manuals Contents Related Manuals 2 pP 3 WarninGS euin uum amari m ee ees 4 Isocyanate Hazard 6 Material Self ignition 6 Moisture Sensitivity of Isocyanates 6 Keep Components A and B Separate 6 Foam Resins with 245 fa Blowing Agents 6 Changing Materials 6 Component Identification 7 IPH SVStEM ue da poo Dau E aoo 7 Human Machine Interface HMI 8 oo PTT 9 Run Screen 11 Conversion Kit Installation 13 Disable Motor Standby Operation 17 Simplified Schematic Shot Controller Wiring 18 Simplified Schematic Shot Controller Electrical 19 Simplified Schematic Alternate Gun Connection 20 id
13. OR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto
14. blem is corrected Disable Learn Mode 8 Navigate to setup screen 8 9 Press the soft key adjacent to the Disable Learn Mode icon Confirm the selection when prompted 10 Exit setup mode by pressing and holding both soft keys for three seconds 312878J Piston Size If the system is off ratio with B side piston size dif ferent from the A side piston the impingers in the gun may need to be adjusted to achieve equal pressures in the A and B side chemical lines For impinger adjustment procedure for the AR Pour Gun see manual 312888 available at WWW graco com 44 552 C mr 2 Size Pump Diameter mm 30 247371 22 225 40 247372 25 629 48 247373 28 092 60 247374 31 496 80 247375 36 297 88 247577 38 024 96 247376 39 802 120 247377 44 552 140 247576 47 955 312878J Setup Define Piston Size If piston diameter editing is aborted prior to con firming the entry of both piston diameters no changes will be saved Remove then re supply power to the shot controller Within 20 seconds of the Idle Run Screen appear ing press and hold both the top soft key and the down arrow key for six seconds When prompted enter password 88888 See Password Protection section on page 23 Edit the A side piston diameter using the up and down arrow keys and the information provided in the preceding table Press the top soft key to edit the B side piston diameter Edit the B side pis
15. e lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturers warnings For com plete information about your material request MSDS forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot sur faces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely Isocyanate Hazard Isocyanate Hazard 11
16. e password and confirm to access the setup screens Entering a Password Use the up and down arrow keys to change the selected digit in the password To move to the next digit press the top soft key If a mistake is made hit the bottom soft key to exit password entry and then re enter setup mode to enter the password x x FiG 12 Password Entry Screen Resetting Password If the password is forgotten the password can be reset without losing the current machine settings or shot data 1 Remove power from the shot controller for 10 sec onds 2 Reapply power to the shot controller 3 When the idle run screen appears immediately press and hold both the top soft key and up arrow key for six seconds The password will then auto matically be reset to 00000 23 Setup Learn Mode Learn mode will need to be used following the installation of the conversion kit the linear sensor or its mounting bracket or the shot controller The IPH units are programmed at the factory so Learn mode will not need to used prior to pouring Learn mode enables the shot controller to learn the left most and right most piston positions To do this the standard piston controls are disabled and the piston is moved left and right using the top soft key With Learn mode enabled the top soft key icon will be a left or right arrow to signify the direction the piston will move when pressed In the usual bottom soft key icon loca
17. e right clevis 261503 312878J Conversion Kit Installation 13 Conversion Kit Installation Install Linear Sensor 12 aol 2 14 13 1 2 FIG 6 10 11 12 14 Place the magnet bracket plate 9 on the left side of the activator plate 21 Pass two socket head cap screws 10 through the bottom two holes of magnet bracket plate 9 and activator plate 21 Place the magnet bracket spacer 8 on top of the activator plate 21 The holes in the magnet bracket spacer 8 are off center Make sure the side with more space between the edge and holes faces down Pass the remaining two socket head cap screws 10 through the top two holes of magnet bracket plate 9 and the two holes in magnet bracket spacer 8 Place the magnet mounting bracket 7 on the right side of the activator plate 21 guiding the four socket head cap screws 10 through the four holes in the bracket Spin the four lock nuts 11 onto the ends of the four socket head cap screws 10 and tighten Apply thread sealant to threads of magnet holder 5 Attach magnet holder 5 to the end of the magnet mounting bracket 7 using nut 15 FIG 7 13 Linear Sensor Assembly ti11796a Assembled View with Front Cover Removed Attach linear sensor bracket 6 to the left hydraulic cylinder port block using two hex head cap screws 12 flat washers 14 and split lock washers 13 Apply
18. e run Screen The machine will send a less than 5V or Low signal specifying it is not ready to receive signals when it is dis pensing in one of the setup screens or when an error code has been generated and has not yet been acknowledged on the shot controller 312878J Dispense Request Line ore FiG 15 on page 28 The gun must be configured to Tap mode to use the dispense request line For the external machine to request a shot Pin 8 Dis pense Request should be momentarily connected to Pin 1 External Machine Return Ground This connec tion should last 150 milliseconds mS to 200 mS before being released If a Dispense Request signal is received when the Ready Status High signal is not being sent the request is ignored Shot Number or Sequence Shot Selection Line NS FiG 15 on page 28 The operating mode can only be changed using the HMI When an external machine tries to select a shot the machine will select a specific shot number if in Shot mode and will select a specific shot posi tion within the selected sequence if in Sequence mode Selecting a shot is done in a manner similar to the Dis pense Request line where Pin 7 should be momen tarily connected to Pin 1 using a semi conductor based output Unlike the Dispense Request line where the line is grounded only once Pin 7 is grounded to Pin 1 repeatedly The period of time between Pin 7 being grounded should equal the period
19. eady to catch the dispensed material Enter Maintenance mode by pressing and holding the bottom soft key for two seconds then park the hydraulic proportioner by selecting the PARK button on the pro portioner display See hydraulic proportioner operation manual 312062 for more information 31 Pressure Relief Procedure 4 Turn PRESSURE RELIEF SPRAY valves SA SB Pressure Relief Procedure re to PRESSURE RELIEF CIRCULATION C2 Route fluid to waste containers or supply tanks Ensure 1 Relieve pressure in gun and perform gun shutdown gauges drop to 0 procedure See gun manual 312888 2 Close gun fluid manifold valves A and B See gun manual 312888 SA Shut off feed pumps and agitator if used ti9879a 5 Engage gun safety lock See gun manual 312888 6 Disconnect gun air line and remove gun fluid mani fold See gun manual 312888 32 3128784 Troubleshooting Troubleshooting Key Error Code Error Icon Fic 17 Error Alert Screen Error Codes key has been pressed key has been pressed for more than 30 more than 30 fe Check shot controller for stuck key shot controller for stuck key seconds Replace shot controller Linear sensor fault often caused if in Learn Check wiring and replace as necessary mode and piston position measured is out Check linear sensor and replace as necessary side the expected range e Learn mode will need to be used
20. ep 3 up or down fractionally to improve the accuracy of the shot delivery 30 Example Assume a programmed shot size of 250cc In this exam ple the dispensed shot size as measured is 271cc Cal culate 250 271 0 9225 Enter the amount 0 92 into the Calibration Factor for the programmed shot Restart Shot Sequence In sequence mode to restart a shot sequence from the first defined shot press and hold the down arrow key for three seconds When prompted hit the top soft key to confirm restarting the sequence Repeat Skip Shot in Sequence To repeat a shot while at the idle run screen press the down arrow key and confirm when prompted To skip a shot while at the idle run screen press the up arrow key and confirm when prompted 312878J Dispense Material A shot can be initiated using either the gun trigger or the Initiate Shot button See Tap and Hold Gun Modes on page 22 Maintenance Mode When using Maintenance mode for anything other than shutting down the machine close the material valves on the coupling block to avoid accidentally dis pensing material See AR Pour Gun manual 312888 for more information To perform cleaning maintenance or other work on the AR Pour Gun without error codes being generated use Maintenance Mode To enter Maintenance Mode press and hold the bottom soft key for two seconds from the idle run screen When in Maintenance mode the gun dispense val
21. es only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS F
22. esistant o rings All other brand names or marks are used for identification purposes and are trademarks of their respective owners 36 312878J Performance Charts Performance Charts 312878J Pressure in psi MPa bar AR Pour Gun Impingers and Reactor Foam Performance Chart 2000 13 8 138 KEY A IPH 25 at 50 Hz B IPH 25 at 60 Hz 1500 C IPH 40 at 50 Hz 10 3 103 0 IPH 40 at 60 Hz E AR C 23 B 1 impingers F AR C 36 C 1 Impingers 1000 G AR C 58 1 impingers 6 9 69 AR D 59 D 1 front impinger AR D 58 C 1 rear impinger 500 3 4 34 0 5 15 25 35 45 55 2 3 6 8 11 4 15 9 20 5 25 0 Flow Rate Ib min kg min Pressure flow curve for model 255811 IPH 40 230V 1 phase not shown Maximum pressure limited to 1700 psi 11 7 MPa 11 7 bar Impingers tested with 100 150 centipoise Mesamoll with a specific gravity of 1 055 37 Graco Ohio Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty appli
23. fumes are present Ground equipment personnel object being sprayed and conductive objects in work area See Grounding instructions Use only Graco grounded hoses Check gun resistance daily If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Do not flush with gun electrostatics on Do not turn on electrostatics until all solvent is removed from system Keep a working fire extinguisher in the work area 4 312878 747 312878J Warnings ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of th
24. hot controller 1 into shot controller bracket 2 Connect the Wire Harnesses See Simplified Schematic Shot Controller Wir ing on page 18 ti11756a FIG 10 28 Remove electrical cabinet front cover CB 16 29 Connect the pump plug to J12 on the motor control board 30 Connect the temp plug to the data connector on the temperature control board 31 Connect wire harness to the linear sensor 32 Connect 3 pin plug to J5 on the motor control board 33 Connect 5 pin plug to J6 on the motor control board 34 Connect the two power leads to the fan fuse block 35 Replace electrical cabinet front cover CB Connect Shot Controller Cables See Simplified Schematic Shot Controller Wir ing on page 18 36 Plug DB25 data cable 151859 into the receptacles on the electrical enclosure cover DB and the shot controller 1 37 Plug power cable 121003 into the electrical enclo sure cover DB and the left receptacle on the shot controller 1 312878J Disable Motor Standby Operation A shot delivered while the Reactor electric motor and hydraulic pump are ramping up to full speed be inaccurate Because of this it is recommended that Motor Standby mode be disabled when the Shot Con troller is installed See the Standby section in the Reac tor operation manual 312062 for information about disabling Standby mode If the Reactor Standby mode has not been disabled and the motor has entered
25. if linear sensor is replaced Dispense valve is stuck open or one of the If dispense valve is stuck the machine will auto material tanks is empty leading to higher matically attempt to release it dispensed quantity than requested e he amount dispensed will be more than requested when this error occurs Fil tank e Adjust E52 alarm delay time from setup screen 4 A piston stroke has taken more than 10 sec Verify that the gun safety is off e Verify that the gun dispense valve is not stuck closed e Verify adequate hydraulic or pneumatic pressure to machine e Inspect for mechanical interference with the pis ton e Verify correct power to the proportioner piston This error code warns of the possibility of e Request a larger shot inconsistent shots but will allow the e Verify that shot volume variation is ok requested shot to occur Shots requiring less than 1 8 of a full piston stroke will trig ger this error code A shot has been requested that is above the Request a smaller shot maximum allowable amount Learn mode failed to learn piston travel e Repeat Learn mode range because e Inspect the linear sensor and replace as neces 1 Piston did not move during Learn mode sary 2 Linear sensor failure 312878J 33 Parts Parts Model Series Hydraulic Proportioner rE Ce 255811 255812 255813 255814 255815 255816 255819 255820 255821 255822 255823 255824 253725 253726
26. is bent d etat Sonet A ae 21 Hydraulic Proportioner Setup 21 Controller 21 Password Protection 23 Learn 24 510 9126 e rc e e AO 25 Optional External Machine Control 26 es eld eee ae 29 SLAW savant osa is exar aet es nannies 29 Change Operating Mode 29 Change Shot Number 29 Change Shot Volume Weight 29 Sequence Mode Options 30 Dispense Material 31 Maintenance Mode 31 Demo Mode 31 Hibernate Mode 31 50205 dome 31 Pressure Relief Procedure 32 Troubleshooting 33 sae ose tase ees 33 6 anaes 34 Hydraulic 34 Conversion Kit 24A024 34 Technical Data 36 Performance 37 Graco Ohio Standard Warranty 38 Graco Ohio 38 Related Manuals These manuals can be found at www graco com Reactor Hydraulic Proportioner Pan peseripton 312062 Reactor
27. nd a shot is initiated To edit a shot navigate to setup screen 2 Press the top soft key and then use the arrow keys to highlight the number of the shot to edit Press the top soft key to select and change the quantity for the selected shot using the up and down arrow keys Press the top soft key to highlight the calibration factor If required use the up and down arrow keys to adjust the calibration factor Refer to Calibration page 30 for more information Press the top soft key to enter the change and then confirm the change when prompted Setup Screen 3 Shot Sequences Setup screen 3 shows the five customizable shot sequences each with a sequence of ten shots Each of the ten shots in each sequence can be changed to any of the shot numbers defined using setup screen 2 If any sequence contains either an undefined shot or one of the positions in the sequence is undefined that shot will be skipped when operating with that sequence 21 Setup To edit a shot sequence navigate to setup screen 3 Hit the top soft key to move to the next screen then use the up and down arrows to highlight a shot sequence Press the top soft key to select the highlighted sequence then use the arrow keys to navigate to the shot in that sequence and hit the top soft key to select Once selected use the arrow keys to change the n shot in the sequence to a different shot number See Setup Screen 2 Shot Number Definitions Set
28. of the pump during the shot delivery This provides a precise and repeatable shot volume However the accuracy of the shot amount may not be sufficient for the application due to many fac tors that are dependent on the specific options and installation Factors such as the dispense valve length of hoses pressure and material temperature may affect the accuracy of the volume dispensed To account for these variables you can calibrate the delivered volume of each programmed shot When a new shot is defined in setup screen 2 the default value of the calibration factor is 1 00 Decrease this value to decrease the shot amount Increase this value to increase the shot amount Use the following procedure to calculate calibration factors You can set the calibra tion factor to any value between 0 20 and 2 00 Calculate Calibration Factors To calculate the calibration factor for a shot 1 Dispense and measure a shot with the calibration factor set to 1 00 default 2 Divide the programmed shot size by the measured shot size If the measured shot is larger than the programmed amount the calibration factor is less than 1 00 If the measured shot is smaller than the pro grammed amount the calibration factor is greater than 1 00 3 Enterthe result of step 2 into the scale factor setting in setup screen 2 for the specific shot 4 Dispense and measure another shot to verify the calibration You can adjust the value entered in st
29. om serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection SKIN INJECTION HAZARD High pressure fluid from dispense valve hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment e Do not point dispense valve at anyone or at any part of the body Do not put your hand over the end of the dispense nozzle Do not stop or deflect leaks with your hand body glove or rag Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses tubes and couplings daily Replace worn or damaged parts immediately FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use and clean equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn lights on or off when flammable
30. or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Ohio Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Toll Free 1 800 746 1334 or Fax 330 966 3006 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original Instructions This manual contains English MM 312878 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO OHIO INC 8400 PORT JACKSON AVE NW NORTH CANTON OH Copyright 2009 Graco Ohio Inc is registered to ISO 9001 WWW graco com Hevised 06 2011
31. ord is disabled s O o D sh 2558 oc 2558 g 285 9 5 205 9 sms CO c 5 Initiate shot 52 0 Ac E 9 After 15 sec D dow Press up 02 55 arrow Ke arrow ke o lt QS m S 52 D O Qo E N U 5 GRACO o d Press dow Press up iB arrow ke arrow ke Turn on HMI O S A Press dow Press up arrow Ke arrow ke c Press ay Press zt arrow k arrow ke N O d Exit setup screens and return to Idle Run Screen by Press dow pressing and holding both soft keys for 3 sec Le Setup Screen 8 Press key t to Fic 4 Screen Navigation Diagram 12 312878J Conversion Kit Installation The IPH 25 and IPH 40 systems include a hydrau lic proportioner and conversion kit 24A024 and are assembled at the factory These instructions are for installing Conversion Kit 24A024 onto an existing H 25 or H 40 hydraulic proportioner See Parts on page 34 for Conversion Kit 24A024 parts Install New Reversing Switch Activator Plate ti11756a FiG 5 1 Remove front cover CA For steps 2 through 4 refer to Proportioning Pump manual 312068 for detailed instructions 2 Remove right clevis 261503 and reversing switch activator plate 3 Install new reversing switching activator plate 21 4 Replac
32. p screens for example from setup screen 1 to setup screen 2 use the up and down arrow keys To navigate within a setup screen for example from the first page of setup screen 6 to the second page of setup screen 6 use the soft keys See FIG 4 on page 12 for illustration of the setup screens and navigation Setup Screen 1 System Data This screen is a collection of system data that includes the shot counter for each programmed shot total piston stroke counter and a separate resettable piston stroke counter The piston stroke counters are displayed on the last screen of setup screen 1 To restart the counter for the resettable piston stroke counter navigate to setup screen number one Press the top soft key to navigate to the next data page Press the top soft key repeatedly until the icon for the bottom soft key is Press the bottom soft key to zero the counter and confirm the selection when prompted 312878J Setup Setup Screen 2 Shot Number Definitions The shot quantity units cubic centimeters or grams for which each shot number quantity is defined is dependent on whether the material specific gravity has been entered See Setup Screen 6 Quantity Units and Gun Configuration on page 22 From setup screen 42 any of the twenty five available shot numbers can be edited Each shot number can be defined so that the machine will dispense the input quantity of material when the shot number is selected a
33. placement Danger and Warning labels tags and cards are available at no cost 312878J Parts 35 Technical Data Technical Data Category Maximum Fluid Working Pressure Fluid Oil Pressure Ratio Fluid Inlets Fluid Outlets Fluid Circulation Ports Maximum Fluid Temperature Maximum Output 10 weight oil at ambient temperature Output per Cycle A and B Models IPH 25 and IPH 40 2000 psi 13 8 MPa 138 bar Model IPH 25 1 91 1 Model IPH 40 1 64 1 Component A ISO 1 2 npt f 250 psi 1 75 MPa 17 5 bar maximum Component B RES 3 4 npt f 250 psi 1 75 MPa 17 5 bar maximum Component B RES 10 JIC 7 8 14 unf with 6 JIC adapter Model IPH 25 22 Ib min 10 kg min 60 Hz Model IPH 40 50 Ib min 23 kg min 60 Hz Model IPH 25 0 063 gal 0 23 liter Model IPH 40 0 076 gal 0 29 liter Line Voltage Requirement 230V 1 phase and 230V 3 phase units 195 264 Vac 50 60 Hz 400V 3 phase units 338 457 Vac 50 60 Hz Amperage Requirement See Models page 3 Heater Power See Models page 3 A and B heaters total no hose Weight IPH 25 Models with 8 0 kW Heaters 535 Ib 243 kg IPH 25 Models with 15 3 kW Heaters 562 Ib 255 kg IPH 40 Models with 12 0 kW Heaters 597 Ib 271 kg IPH 40 Models with 15 3 kW Heaters 597 Ib 271 kg Aluminum stainless steel zinc plated carbon steel brass carbide chrome fluoroelastomer PTFE ultra high molecular weight polyethylene chemically r
34. se Watts gal liter Ratio psi MPa bar 255823 B 41 400V 3 26600 15300 50 23 0 076 0 29 1 64 1 2000 13 8 138 CONVERSION KIT gt 24 024 Conversion kit for existing 25 H 40 hydraulic proportioners Full load amps with all devices operating at maximum capabilities Fuse requirements at various flow rates and mix chamber sizes may be less Maximum flow rate given for 60 Hz operation For 50 Hz operation maximum flow rate is 5 6 of 60 Hz maximum flow 312878J 3 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable 2 TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDSSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear impervious gloves when spraying or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you fr
35. temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Keep the ISO lube pump reservoir if installed filled with Graco Throat Seal Liquid TSL Part 206995 The lubricant creates a barrier between the ISO and the atmosphere e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been contam inated from the other side e Always lubricate threaded parts with ISO pump oil or grease when reassembling Keep Components A and B Separate CAUTION To prevent cross contamination of the equipment s wetted parts never interchange component A isocy anate and component B resin parts Foam Resins with 245 fa Blowing Agents New foam blowing agents will froth at temperatures above 90 F 33 C when not under pressure especially if agitated To reduce frothing minimize preheating in a circulation system Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing e Check with your material manufacturer for chemical compatibility e Most materials use ISO on the A side but
36. the selection when prompted Tap and Hold Gun Modes Tap mode and Hold mode define how the machine responds to pulling releasing the gun trigger and if enabled pressing releasing the Initiate Shot button on the HMI When in manual mode the machine will only shoot when the gun trigger or Initiate Shot button is held regardless of which mode or Hold is selected In Tap mode signified by the icon lA a shot is first initiated by tapping and releasing the gun trigger or Initi ate Shot button Once a shot is started the shot can only be stopped or started again by tapping the trigger or the bottom soft key The shot will continue until the predefined time elapses or the trigger or bottom soft key is tapped In Hold mode signified by the icon 14 shots initi ated by pulling the gun trigger or pushing the Initiate Shot button Unlike Tap mode the shot will only con tinue as long as the trigger or button is held If the trigger or button is held longer than the predefined duration of the selected shot the shot will end when the predefined duration elapses To toggle between Tap and Hold mode nav igate to setup screen 6 and press the top soft key which will have next to it either the Tap or Hold icon 312878J Setup Screen 7 Enable Disable Run Screen Shot Editing or Initiate Shot button Enabling the
37. thread sealant to remaining nut 15 Install linear sensor 4 in the linear sensor bracket 6 using remaining nut 15 Pass wiring harness from linear sensor 4 through opening in top of electrical cabinet DE Replace front cover CA 312878J Install Electrical Enclosure DA Key DA Screw Conversion Kit Installation ti11757a DB Electrical enclosure cover DC Electrical enclosure DD Wire access cover screws DE Electrical cabinet FIG 8 18 19 20 21 22 Remove three screws DD holding wire access cover to the electrical cabinet Remove wire access cover from the left side of the electrical cabinet DF The wire access cover will not be re used Remove electrical enclosure cover DB from the electrical enclosure DC by removing two screws DA Pass wire harness from electrical enclosure cover DB through back of electrical enclosure DC and into electrical cabinet DE Install electrical enclosure DC to side of electrical cabinet DE using three screws DD 312878J 23 Install electrical enclosure cover DB to electrical enclosure using two screws DA 15 Conversion Kit Installation Install Shot Controller ti11758a FIG 9 24 Remove the two left side crown nuts EA from the display EC 25 Apply thread sealant to threads of crown nuts EA 26 Install shot controller bracket 2 to display EC using crown nuts EA 27 Snap s
38. tion the left most and right most piston positions obtained from using Learn mode will be shown Fic 13 Run Screen with Learn Mode Enabled Learn Piston Left most and Right most Positions Enable Learn Mode 1 Change the operating mode to Manual see Change Operating Mode section on page 29 2 Navigate to setup screen 8 See FIG 4 on page 12 3 Select the top soft key with the Enter Learn Mode icon and confirm the selection when prompted See Icons section on page 9 4 Press and hold both the top and bottom soft keys for three seconds to exit the setup screens 24 Obtain Piston Range Information To view the physical piston movement remove the front cover CA from the machine Replace the cover when finished using Learn mode 5 Using a bucket to catch the dispensed material trig ger the gun until the piston reaches the left most or right most position 6 Manually reverse piston direction by pressing the top soft key 7 Repeat steps 5 and 6 until the piston range dis played in the bottom right corner of the screen remains constant If the piston range displayed in the bottom right cor ner of the screen contains a number outside the range of 200 to 4650 error code E50 will be gener ated A number outside this range means that either the linear position sensor is not properly installed or there is a problem with the shot control ler electronics Error code E50 will be generated until the pro
39. ton diameter using the up and down keys and the information provided in the pre ceding table Press the top soft key to confirm the piston entries The shot controller will then return to the idle run Screen 25 Setup Optional External Machine Control 8 All electrical work must be done by a technician knowledgeable in electronics CAUTION The external machine must use a semi conductor based output such as an NPN transistor An optional external machine control interface can be installed if desired The external machine will be able to select specific shots and to initiate shots CAUTION The external machine will not supply any voltage through any of the lines It will only ground the received signals from Pins 7 and 8 to Pin 1 as needed 26 GA Pin 1 External Machine Return Ground GB Pin 2 Not used GC Pin 3 Not used GD Pin 4 Not Used GE Pin 5 Ground for Cable Shields GF Pin 6 Not used GG Pin 7 Shot Number or Sequence n Shot Selection GH Pin 8 Dispense Request GJ Pin 9 Ready Status Ready Status Line yor FiG 15 on page 28 The Ready Status line tells the external machine when the shot controller is ready to receive signals This line has two states High and Low When it is High there is 24V and when it is Low there is less than 5V The machine will send 24V or High signal specifying it is ready to receive inputs when it is at the idl
40. up Screen 4 Adjusting E52 Error Delay Smaller piston sizes and longer hoses will require a longer delay When finished dispensing the piston will continue to travel slightly before being stopped and if the piston trav els longer than expected the E52 error will occur If the E52 error code is triggered often the likelihood of the alarm triggering can be lowered by extending the time the machine waits before triggering the alarm To edit the E52 error delay navigate to Setup Screen 4 then press the top soft key to enter editing mode Use the up and down arrow keys to edit the time then press the top soft key to enter the change Setup Screen 5 Password Protection See Password Protection section on page 23 Setup Screen 6 Quantity Units and Gun Configuration Setup screen 6 serves two functions toggling between measuring shot quantity in cubic centimeters or grams and toggling between gun modes Tap and Hold 22 Quantity Units To configure the machine to display shot quantity in grams when it is currently displaying cubic centimeters navigate to setup screen 6 Press the top soft key then enter the specific gravity of the dispensed and mixed material using the arrow keys Press the top soft key when finished to confirm To configure the machine to display shot sizes in cubic centimeters when it is currently displaying in grams navigate to setup screen 6 Press the top soft key then confirm
41. ve can be opened and closed by pressing the top soft key twice or by pressing the gun trigger Once the top soft key has been used to open or close the gun dispense valve the gun trigger will be disabled To regain the abil ity to open and close the gun using the trigger after using the top soft key exit and re enter Maintenance mode 312878J Operation Demo Mode Demo mode is an alternate operating mode that is iden tical to standard operation but with a few exceptions When in Demo mode pouring control of the gun and hydraulic proportioner and Learn mode are all disabled Also settings and passwords saved in Demo mode are separate from settings saved in normal operation Enter Exit Demo mode 1 Remove then resupply power to the shot controller 2 Within five seconds of the idle run screen appear ing press and hold both the bottom soft key and the down arrow key for six seconds A D in the bottom left corner of the HMI screen will be shown when in Demo mode Hibernate Mode The HMI will enter hibernate mode when idle for six min utes To exit hibernate mode press the up or down arrow key or trigger the gun If hibernate mode is exited by triggering the gun the HMI will light to half brightness To have the HMI display light to full brightness press any key Shutdown When shutting down the hydraulic proportioner a small amount of material will be dispensed Have a sheet of cardboard or other item r
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